A global OEM manufacturer faced a major setback during a product launch with costs surging 60% over budget, lead times extended fivefold, and the release was delayed over a year, threatening market relevance and internal confidence.

Our team led a full transformation of the operating model and value stream. We redefined the system from the ground up, starting with a strategic supply chain restructuring that improved long lead-time component availability by 70%. Simultaneously, we redesigned the manufacturing system through product family segmentation, reducing manufacturing lead time by 83% and enabled a more flexible and scalable production flow. Support functions were streamlined to eliminate bottlenecks and improve coordination.

To ensure sustainability, we implemented a smart manufacturing model that captured real-time operational data, enabling faster issue resolution, predictive insights, and informed decision-making. These integrated changes stabilized the launch and drove costs back to target, turning a troubled rollout into a model of operational excellence and innovation.